In most industries, financial pressures are the driving factor behind almost all operational decisions, and this is no less true of the application of condition monitoring tools. Traditionally, when the pressure on budgets is higher, operators assert that there is no money available for condition monitoring tools, as well as the training required to apply them. However, the value that effective condition monitoring can deliver should not be overlooked. By employing a suite of tools and reliability-centred maintenance strategies, operators can optimise efficiency and manage costs in order to maximise their returns.  

For both oil analysis and acoustic emissions monitoring, onsite instruments enable rapid testing, informing the actions engineers take to maximise the operational life and output of the asset. Combined with online sensor technology designed to provide real time data, alerting engineers to issues within the system at the earliest possible stage, operators are best armed to prevent damage before costs are incurred through repairs and downtime. Recent developments in condition monitoring are moving increasingly towards online monitoring tools, sensors which continuously feed back to a central point where data is collected and analysed by experts without the need to physically dispatch them to the asset. By de-skilling the condition monitoring technology, overheads are kept lower and the need for extensive and costly training is reduced, once again maximising potential cost savings.

As the lifeblood of many valuable assets, it is vital that the condition of lubricating oil is closely monitored and that engineers have the accurate information they need quickly. With tight budgets across the board, maximising the life of lubricating oil is paramount to protecting the operational lifespan of the asset, achieving significant cost savings and operational efficiencies. Monitoring the condition of oil is by no means a new practice. However, the way in which used oil analysis is carried out has evolved in recent years, moving towards a combined approach of online and offline tools, to obtain a detailed and accurate picture of the condition of the asset. 

An important aspect of condition monitoring is to consider the presence of metallic debris in lubricating oil, as a key indication of wear in the system within which it is deployed. Wear debris sensors employ technology to classify the size and material composition of both ferrous and non-ferrous metallic debris, therefore indicating abnormal conditions with the systems before costly damage is caused. The Parker Kittiwake Metallic Wear Debris Sensor (MWDS) recently achieved the industry-leading American Society for Testing Materials (ASTM) D7917-2014 standard for testing metallic wear. The sensor is ATEX Zone 1 applications for hazardous environments, and with both digital and analogue outputs, provides instant data including the size and number of metallic particles as well as the rate of generation. When combined with a comprehensive suite of condition monitoring tools, the sensor aids operators in planning maintenance with the least possible impact on schedule and cost, thereby preventing costly unexpected damage occurring on vital system components.

Traditional vibration analysis has provided a trusted approach to condition monitoring for several decades, it is a complex science and requires sophisticated knowledge and understanding. Acoustic emission technology, however, places the ability to recognise the early signs of damage directly into the hands of the engineer. Parker believes its approach to acoustic emissions monitoring is a viable alternative, extending and simplifying traditional practices and making them accessible to anyone. Parker’s MHC instruments, for example, monitor high frequency acoustic emissions signals naturally generated by deterioration in rotating machinery, providing engineers with condition-related information instantly.